Method of making an absorbent article with prefastened side panels and absorbent articles made by the same

ABSTRACT

A method of making a prefastened disposable absorbent article includes providing a continuous web of interconnected absorbent articles and releasably attaching a pair of opposed side panels to one of the waist regions on each of the absorbent articles. Each of the opposed side panels includes a primary fastener which releasably engages the one waist region to provide the releasable attachment. Each of the side panels also defines side portions which extend laterally outward beyond the side edges of the absorbent article in the one waist region. The continuous web is selectively cut into discrete absorbent articles which are then folded about a fold line extending in a lateral direction through the crotch region of the article thereby positioning the waist regions of the article in a facing relationship. The method further includes securing the side portions of the side panels to the side edges of the absorbent article in the opposite waist region to provide the prefastened absorbent article.

This application is a divisional of application Ser. No. 09/100,825entitled METHOD OF MAKING AN ABSORBENT ARTICLE WITH PREFASTENED SIDEPANELS AND ABSORBENT ARTICLES MADE BY THE SAME and filed in the U.S.Patent and Trademark Office on Jun. 19, 1998. The entirety ofapplication Ser. No. 09/100,825 now U.S. Pat. No. 6,036,805 is herebyincorporated by reference.

FIELD OF THE INVENTION

The present invention relates to disposable absorbent articles which areadapted to contain body exudates. More particularly, the presentinvention relates to methods of making absorbent articles havingprefastened side panels and absorbent articles made by the same.

BACKGROUND OF THE INVENTION

It is desired that absorbent articles such as diapers, training pants orincontinence garments provide a close, comfortable fit about the wearerand contain body exudates. Moreover, it is desirable that such absorbentarticles, after being soiled, can be removed from the wearer in aconvenient and clean manner without undesirably soiling the care giveror surrounding area such as the clothes of the wearer. In certaincircumstances, it is also desirable that such absorbent articles arecapable of being pulled up or down over the hips of the wearer to allowthe wearer or caregiver to easily pull the article on and easily removethe article if it has not been soiled. For example, such absorbentarticles can assist in the toilet training of children.

Conventional diapers have typically included a front waist portion and aback waist portion which are releasably connected about the hips of thewearer during use by conventional fasteners such as adhesive tapefasteners or hook and loop type fasteners. For example, the conventionalfasteners have typically included a pair of fasteners, such as adhesivetape tabs, located on the outermost corners of the diaper in the backwaist region of the diaper and a complimentary fastener, such as ataping panel, located on the outer surface of the outer cover of thediaper in the front waist portion of the diaper. In such aconfiguration, the diaper has been positioned between the legs of thewearer and the adhesive tape tabs have been releasably attached to thetaping panel to secure the back waist portion to the front waist portionof the diaper to secure the diaper about the waist of the wearer. Suchconventional diapers are easy to fasten about and remove from the wearerafter use without undesirably soiling the care giver. However, suchconventional diapers are not provided in a prefastened configuration andthus are not configured to be pulled up or down over the hips of thewearer when the fasteners are attached.

Several attempts have been made to provide absorbent articles whicheffectively contain body exudates, are capable of being pulled up ordown over the hips of the wearer and provide ease of cleaning andremoval after being soiled. For example, some conventional absorbentarticles, such as conventional training pants, have included integralside panels which connect the front waist portion to the back waistportion of the absorbent article. The side panels have been madestretchable such that the waist opening of the absorbent article canexpand to allow the absorbent article to be pulled up or down over thehips of the wearer if desired. Such side panels have also been designedsuch that they may be torn to remove the training pant from the wearerafter it has been soiled.

However, many of such attempts have not been completely satisfactory.For example, absorbent articles such as training pants have not alwaysbeen able to achieve a close conforming fit to the wearer while stillbeing able to expand enough to be pulled up and down over the hips ofthe wearer. Often such training pants fit the waist of the wearerloosely which can undesirably result in leaks. As a result, many of sucharticles have not contained bodily exudates as effectively asconventional diaper-type articles which can be adjusted to achieve amore conforming fit to the wearer. Moreover, the removal of soiledabsorbent articles which have integral side panels, such as conventionaltraining pants, has not always been completely satisfactory. Forexample, the side panels have been difficult to tear when attempting toremove the article from the waist of the wearer instead of pulling thearticle down over the hips of the wearer.

Accordingly, despite the attempts to develop improved absorbentarticles, there remains a need for absorbent articles which can providethe benefits of conventional training pants and conventional diapers.That is, there remains a need for absorbent articles which conform tothe wearer to effectively contain bodily exudates, which are capable ofbeing pulled up and down over the hips and buttocks of the wearerwithout opening, and which are readily secured about and removed fromthe wearer in a convenient and clean manner. Moreover, there is a needfor improved methods of reliably and consistently making such absorbentarticles.

SUMMARY OF THE INVENTION

In response to the difficulties and problems discussed above, newmethods of making a prefastened disposable absorbent articles which havean adjustable fastening system have been discovered. In one aspect, thepresent invention concerns a method of making a prefastened disposableabsorbent article which includes providing a continuous web ofinterconnected absorbent articles, releasably attaching a pair ofopposed side panels to one of the waist regions on each of theinterconnected absorbent articles, selectively cutting the continuousweb into discrete absorbent articles, folding each of the discreteabsorbent articles thereby positioning the waist regions in a facingrelationship; and securing side portions of the side panels to the sideedges of the article in the opposite waist region to provide theprefastened absorbent article. Each of the opposed side panels includesa primary fastener thereon which releasably engages the one waist regionto provide the releasable attachment. Each of the side portions of theside panels extends laterally outward beyond the side edges of theabsorbent article in the one waist region for securement to the sideedges of the opposite waist region.

In another aspect, the present invention concerns a method of making aprefastened disposable absorbent article which defines a front waistregion, a back waist region, a crotch region which extends between andconnects the waist regions, a pair of opposed side edges and a pair ofopposed waist edges. The method comprises the steps of:

a) providing a continuously moving web of outer cover material;

b) intermittently connecting multiple absorbent chassis to the outercover material to provide a continuously moving web of interconnectedabsorbent articles each of which includes one of the absorbent chassis;

c) releasably attaching a pair of opposed side panels to the front waistregion on each of the absorbent articles wherein each of the opposedside panels includes a primary fastener thereon which releasably engagesan outer surface of the absorbent article in the front waist region andwherein each of the side panels defines side portions which extendlaterally outward beyond the side edges of the absorbent article in thefront waist region;

d) releasably bonding the side panels to the front waist region toassist the primary fasteners in providing the releasable attachment ofthe side panels to the front waist region;

e) selectively cutting the continuous web of interconnected absorbentarticles into discrete absorbent articles;

f) folding each of the discrete absorbent articles about a fold lineextending in a lateral direction through the crotch region of theabsorbent article thereby positioning the waist regions of the absorbentarticle in a facing relationship; and

g) securing the side portions of the side panels to the side edges ofthe absorbent article in the back waist region to provide theprefastened absorbent article.

In yet another aspect, the present invention concerns a prefasteneddisposable absorbent article which defines a front waist region, a backwaist region, a crotch region which extends between and connects thewaist regions, a pair of opposed side edges and a pair of opposed waistedges. The absorbent article includes a pair of opposed side panelswhich define side portions which are attached to the laterally opposedside edges of the back waist region of the absorbent article. The sidepanels include a primary fastener located thereon which releasablyengages an outer surface of the absorbent article in the front waistregion to provide the prefastened absorbent article. The absorbentarticle also includes a pair of releasable side bonds which are locatedon the side panels between the primary fastener and the side portion.The releasable side bonds releasably connect the side panels to thefront waist region to assist the primary fasteners in maintaining theprefastened absorbent article in a prefastened condition.

In still another aspect, the present invention concerns a prefasteneddisposable absorbent article which defines a front waist region, a backwaist region, a crotch region which extends between and connects thewaist regions, a pair of opposed side edges and a pair of opposed waistedges. The absorbent article includes a pair of opposed side panelswhich define side portions which are attached to the laterally opposedside edges of the back waist region of the absorbent article. The sidepanels include a primary fastener located thereon which releasablyengages an outer surface of the absorbent article in the front waistregion to provide the prefastened absorbent article. The prefastenedabsorbent article is made by a process which includes:

a) releasably engaging the primary fastener on each of the opposed sidepanels to the outer surface of the absorbent article in the front waistregion;

b) folding the absorbent article about a fold line extending in alateral direction through the crotch region of the absorbent articlethereby positioning the waist regions in a facing relationship; and

c) securing the side portions of the side panels to the side edges ofthe absorbent article in the back waist region to provide theprefastened absorbent article.

The present invention advantageously provides methods of makingprefastened disposable absorbent articles which include an adjustablefastening system for improved fit and performance and absorbent articlesmade by the same. In particular, the present invention provides methodsof attaching prefastened side panels to and folding a disposableabsorbent articles in a reliable and consistent manner. The absorbentarticles of the present invention are capable of being reliably pulledup or down over the hips of the wearer to assist in the toilet trainingof the wearer similar to conventional training pants. Moreover, similarto conventional diapers, the absorbent articles of the present inventioncan advantageously be applied to and removed from the wearer after theyhave been soiled with relative ease and cleanliness.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be more fully understood and furtheradvantages will become apparent when reference is made to the followingdetailed description of the invention and the accompanying drawingswherein like numerals represent like elements. The drawings are merelyrepresentative and are not intended to limit the scope of the appendedclaims.

FIG. 1 representatively shows a schematic view of an example of a methodof making a prefastened disposable absorbent article according to thepresent invention;

FIG. 2 representatively shows a plan view of the steps involved in themethod of FIG. 1;

FIG. 3 representatively shows a side view of an example of a prefasteneddisposable absorbent article made according to the methods of thepresent invention;

FIG. 4 representatively shows a plan view of the disposable absorbentarticle of FIG. 3 in an unfastened, stretched and laid flat conditionwith the surface of the article which contacts the wearer facing theviewer; and

FIG. 5 representatively shows a plan view of the disposable absorbentarticle of FIG. 3 in an unfastened, stretched and laid flat conditionwith the surface of the article which contacts the wearer's clothingfacing the viewer.

DETAILED DESCRIPTION OF THE INVENTION

The present invention concerns methods of making prefastened disposableabsorbent articles which are configured to closely conform to the bodyof the wearer to effectively contain body exudates while being capableof being pulled up or down over the hips and buttocks of the wearer andprefastened absorbent articles made according to the same. Theprefastened disposable absorbent articles can also be easily secured toand removed directly from the waist of the wearer. As such, theprefastened absorbent articles of the present invention can function ina similar manner to conventional training pants when left in theprefastened configuration or they can be unfastened prior to or duringuse to function in a manner similar to conventional diapers. Thedisposable absorbent articles are adapted to be worn adjacent to thebody of a wearer to absorb and contain various exudates discharged fromthe body. As used herein, the term “disposable” refers to articles whichare intended to be discarded after a limited use and which are notintended to be laundered or otherwise restored for reuse.

The methods of making the disposable absorbent articles and the articlesmade by the same of the present invention will be described in terms ofa disposable diaper article which is adapted to be worn by infants aboutthe lower torso. In particular, the methods will be described in termsof a method of making a prefastened disposable absorbent diaper havingprefastened side panels. It is understood that the methods of thepresent invention are equally adaptable for use in making other types ofabsorbent articles such as adult incontinent products, training pants,feminine hygiene products, other personal care or health care garments,and the like.

FIGS. 1 and 2 representatively illustrate an example of a method ofmaking a prefastened disposable absorbent article according to thepresent invention. FIG. 3 further representatively illustrates anexample of a prefastened disposable diaper, as generally indicated at20, made according to the methods of the present invention. FIGS. 4 and5 representatively illustrate the prefastened diaper of FIG. 3 in anunfastened, stretched and laid flat configuration. As illustrated inFIGS. 3-5, the diaper 20 defines a front waist region 22, a back waistregion 24, a crotch region 26 which extends between and connects thefront and back waist regions 22 and 24 and a pair of laterally opposedside panels 28. The diaper 20 further defines a pair of laterallyopposed side edges 30, a pair of longitudinally opposed waist edges 32,an interior surface 34 which is configured to contact the wearer, anouter surface 36 opposite the interior surface 34, a longitudinaldirection 38 and a lateral direction 40.

The front waist region 22 comprises the portion of the diaper 20 which,when worn, is positioned on the front of the wearer while the back waistregion 24 comprises the portion of the diaper 20 which, when worn, ispositioned on the back of the wearer. The crotch region 26 of the diaper20 comprises the portion of the diaper 20 which, when worn, ispositioned between the legs of the wearer and covers the lower torso ofthe wearer. The side panels 28 comprise the portions of the diaperwhich, when worn, are positioned on the side hip regions of the wearer.The laterally opposed side edges 30 of the diaper 20 generally defineleg openings which may be curvilinear. The waist edges 30 of the diaper20 are configured to encircle the waist of the wearer when worn andprovide a waist opening when fastened which defines a waist perimeterdimension.

The illustrated diaper 20 includes an outer cover 42, an absorbentchassis 44 and a fastening system 60. The fastening system 60 includes apair of primary fasteners 62 and a pair of laterally opposed releasableside bonds 64 located on the side panels 28 of the diaper 20. Theabsorbent chassis 44 is configured to contain and/or absorb any bodyexudates discharged from the wearer. Whereas, the outer cover 42,primary fasteners 62 and releasable side bonds 64 are configured tomaintain the diaper 20 about the waist of the wearer, conceal theabsorbent chassis 44 from view, and provide a garment-like appearance.The diaper 20 may further include leg elastics 52, containment flaps 54and waist elastics 56 as are known to those skilled in the art. Itshould be recognized that individual components of the diaper 20 may beoptional depending upon the intended use of the diaper 20.

The methods of the different aspects of the present invention aredirected at reliably and consistently providing prefastened disposableabsorbent articles such as that representatively illustrated in FIG. 3.For example, as representatively illustrated in FIGS. 1 and 2, themethods can include providing a continuous web of interconnected diapers80 moving in the direction indicated by arrow 82. In such aconfiguration, the front waist region 22 of the leading diaper 20 may beconnected to the back waist region 24 of the trailing diaper 20 to formthe continuous web of interconnected diapers 80. Alternatively, the backwaist region 24 of the leading diaper may be connected to the frontwaist region 22 of the trailing diaper or the diapers may be arranged ina front-to-front/back-to-back relationship.

The continuous web of interconnected diapers 80 may be provided by meansknown to those skilled in the art. For example, a web of interconnecteddiapers 80, such as the diaper illustrated in FIG. 3, may be provided byfirst providing a continuously moving web of material for the outercover 42. Individual absorbent chassis 44 for each diaper 20 may then beintermittently connected to the continuously moving web of outer covermaterial at spaced apart locations. Additional components, such as theleg elastics 52, containment flaps 54 and waist elastics 56, may also beconnected to the continuously moving web of outer cover material or theindividual absorbent chassis connected thereto to provide the web ofinterconnected diapers 80. The different components of the diaper 20 maybe connected together by means known to those skilled in the art suchas, for example, adhesive, thermal or ultrasonic bonding. Desirably,most of the components are connected using ultrasonic bonding forimproved manufacturing efficiency and reduced raw material cost.

As illustrated in FIG. 1, a pair of laterally opposed side panels 28having primary fasteners 62 attached thereto are also releasablyattached to one of the waist regions 22 and 24 of each diaper 20 on thecontinuously moving web of interconnected diapers 80. The side panels 28are releasably attached to each diaper 20 by releasably engaging theprimary fasteners 62 with the outer surface 36 of each diaper 20 in therespective waist region 22 or 24. For example, as representativelyillustrated in FIGS. 1 and 2, the primary fasteners 62 located on eachof the laterally opposed side panels 28 may be releasably engaged withthe outer surface 36 of the diaper 20 in the front waist region 22 ofthe diaper 20. Alternatively, the fasteners 62 located on the sidepanels 28 may be releasably engaged with the outer surface 36 of thediaper in the back waist region 24. As discussed below, each diaper 20may include an attachment panel 66 located on the outer cover 42 towhich the primary fasteners 62 releasably engage. Alternatively, theprimary fasteners 62 may releasably engage the outer cover 42 of thediaper 20 directly without requiring an separate fastening panel.

When the primary fasteners 62 have been releasably engaged with theouter surface 36 of the diaper 20, the laterally opposed side panels 28define side portions 70 which extend in the lateral direction 40 outwardbeyond the opposed side edges 30 of the diaper 20 in the respectivewaist region 22 or 24. For example, as illustrated in FIG. 2, theopposed side panels 28 may define side portions 70 which extendlaterally beyond the side edges 30 of the diaper 20 in the front waistregion 22. In such a configuration, the side portions 70 are configuredto be secured to the side edges 30 of the diaper 20 in the back waistregion 24 to provide the prefastened diaper 20. Desirably, the sideportions 70 of the side panels 28 extend outward beyond the side edges30 a distance of at least about 0.5 centimeters and more desirably atleast about 1.0 centimeters in the lateral direction 40. Such distanceprovide sufficient material for securement to the side edges 30 of thediaper 20 in the opposite waist region. To facilitate the attachment ofthe side portions 70 of the side panels 28 to the opposite waist region22 or 24, it is desirably that the waist region to which the primaryfasteners are releasably engaged defines a width in the lateraldirection 40 which is smaller than the width of the opposite waistregion in the lateral direction 40. For example, in the illustratedembodiments, it is desired that the width of the front waist region 22be smaller than the width of the back waist region 24 such that the sideportions 70 of the side panels 28 are in a facing relationship with theside edges 30 of the diaper 20 in the back waist region 24 for improvedmanufacturing.

The laterally opposed side panels 28 may be supplied by means known tothose skilled in the art. For example, as illustrated in FIG. 1, twowebs of spaced apart, interconnected side panels 110 having the primaryfasteners 62 attached thereto may be provided. The webs of side panelsmay then be passed through the slip cutter 112 which intermittently cutsthe respective webs of side panels 110 into discrete side panels 28. Theprimary fasteners 62 on each discrete side panel 28 are thenintermittently releasably engaged with the outer surface 36 of eachdiaper at spaced apart locations along the side edges 30 of each diaperon the web of interconnected diapers 80. The releasable engagement ofthe fasteners 62 with the outer surface 36 of the diaper 20 may beensured by passing the fasteners 62 and web 80 between a pair ofrotating nip rolls (not shown) which apply pressure to between thefasteners 62 and outer surface 36.

As illustrated in FIGS. 1 and 2, the opposed side panels 28 may furtherbe releasably bonded to the outer surface 36 of the diaper 20 to assistthe primary fasteners 62 in maintaining the side panels 28 releasablyattached to the diaper 20. Such releasable bonds may be provided bypassing the diaper 20 through bonder 100, as illustrated in FIG. 1. Forexample, bonder 100 may be configured to releasably bond the section ofthe side panels 28 between the primary fasteners 62 and the sideportions 70 to the outer surface 36 of the diaper 20 in the front waistregion 22 at bond points 64, as representatively illustrated in FIG. 2.The term “releasably bond” as used herein refers to a bond which has arelatively low peel strength such that the bond can be broken by thecaregiver if desired to assist in removing the diaper 20 from the wearerwithout tearing or severely damaging the other portions of the diaper20. The releasable bonds may otherwise be broken prior to applying thediaper 20 to the wearer if it is desired to apply the prefastened diaperof the invention in a similar manner to conventional diapers. Thespecific values of the desired peel strength of the bond are set forthherein in conjunction with the detailed description of the diaper 20illustrated in FIGS. 3-5.

The releasable bonds 64 assist in maintaining the diaper 20 in theprefastened configuration while it is being pulled on or off over thehips of the wearer. The releasable bonds 64 further help maintain theside panels 28 in alignment until they are permanently secured to theopposite waist region of the diaper 20 after the diaper 20 is folded.The releasable side bonds 64 also provide improved hip coverage andprevent rollover or folding of the side edges 30 and waist edges 32 ofthe prefastened diaper 20 as it is pulled over the wearers hips. Suchprevention of rollovers and foldovers can reduce the level of contactbetween the fasteners and the skin of the wearer which can desirablyresult in reduced skin irritation and redness.

As shown in FIGS. 1 and 2, the releasable side bonds 64 are locatedlaterally outward of the primary fasteners 62 on the side panels 28 whenthe side panels 28 are releasably attached to the outer surface 36 ofthe diaper 20. As used herein, the term “outward” refers to a distancein the lateral direction 40 away from a longitudinal centerline of thediaper 20. In such a configuration, the releasable side bonds 64 connecta section of each side panel 28 laterally outward of the primaryfasteners 62 to the outer surface 36 of the diaper 20. Desirably, thereleasable side bonds 64 connect the side panels 28 to the side edges 30of the front waist region 22. For example, as illustrated, thereleasable side bonds 64 may releasably bond the longitudinally opposededges of the side panels 28 to the side edges 30 of the front waistregion 22. In such a configuration, the releasable bonds 64 also assistin preventing the side and waist edges 30 and 32 of the diaper 20 fromrolling over as the diaper 20 is pulled on or taken off.

When the side panels 28 are releasably attached to the outer surface 36of the diaper 20 as illustrated in FIG. 2, the releasable side bonds 64are located on the side panels 28 laterally outward from the primaryfastener 62 a distance 68 to prevent relative movement or shiftingbetween the side panels 28 and the front and back waist regions 22 and24 when the diaper 20 is being used. In a particular embodiment, atleast a portion of each of the releasable side bonds 64 is located onthe side panels 28 laterally outward from the primary fasteners 62 adistance 68 of at least about 1.0 centimeters and desirably at leastabout 2.0 centimeters. When the distance 68 is less than the values setforth above, the side panels 28 and front and back waist regions 22 and24 may undesirably shift with respect to each other during theapplication or use of the diaper 20. Such shifting may adversely affectthe fit of the diaper 20 on the wearer which can undesirably lead toincreased leakage.

Suitable bonding equipment which can be used to provide the releasablebonds 64 is well known to those skilled in the art. Desirably, thebonder 100 is an ultrasonic bonder for improved efficiency and costeffectiveness. For example, as illustrated in FIG. 1, the bonder 100 mayinclude one or more rotary ultrasonic horns 102 and an anvil roll 104between which the web of diapers 80 is passed to provide the releasablebonds 64. Suitable rotary ultrasonic horns are described in U.S. Pat.No. 5,110,403 to Ehlert, the disclosure of which is hereby incorporatedby reference. Such rotary ultrasonic horns 102 generally have a diameterof from about 5to about 20 centimeters and a width of from about 2 toabout 15 centimeters. Alternatively, the ultrasonic horn 102 may be astationary ultrasonic horn as are also known to those skilled in theart. Other suitable ultrasonic horns and ultrasonic bonders arecommercially available from Branson Sonic Power Company, a businesshaving offices in Danbury, Connecticut. The bonder 100 could otherwisebe a thermal or adhesive bonder as are known to provide the releasablebonds 64.

The bonder 100 may be configured to provide the releasable bonds 64 in avariety of patterns and shapes or sizes. For example, the releasablebonds 64 may be provided as a pattern of points, dots, circles, squares,triangles and the like which may be arranged in a linear or nonlinearconfiguration. In the illustrated embodiments, such patterns may belocated on the bonding horn 102 or the anvil roll 104. Desirably, thepattern is located on the anvil roll 104 for improved manufacturingefficiency.

The continuous web of interconnected diapers 80 is passed through cutter84 which selectively cuts the web 80 into discrete, individual diapers20. Such cutters are generally known to those skilled in the art and mayinclude, for example, the combination of a cutting roll 86 and anvilroll 88 through which the web 80 travels. The anvil roll 88 may includea hardened steel rotating roll while the cutting roll 86 may include oneor more flexible hardened steel blades clamped on to another rotatingroll. The pinching force between the blade on the cutting roll and theanvil roll creates the cut. The cutting roll 86 may have one or moreblades depending upon the desired distance between the cuts. The cutter84 may further be configured to provide a spacing between the individualcut pieces after they are cut. Such a spacing can be provided bytransferring the cut pieces away from the cutter at a higher speed thanthe speed at which the web is provided to the cutter. For example, slipcutter 112 is desirably configured in such a manner.

The discrete diapers 20 are then folded in a conventional blade folder90 about fold line 92 on the diaper 20. As such, the waist regions 22and 24 of each diaper are positioned in a facing relationship with theside portions 70 of the side panels extending laterally outward beyondthe side edges 30 of the diaper 20 in the front waist region 22 asillustrated in FIGS. 1 and 2. The fold line 92 extends in a lateraldirection through the crotch region 26 of the diaper 20. Desirably, eachdiaper 20 is consistently folded about fold line 92 such that the waistedges 32 of the diaper 20 in the front and back waist region 22 and 24align with each other.

Suitable blade folders to provide the folding are well known to thoseskilled in the art. For example, as illustrated in FIG. 1, the bladefolder 90 may include a pair of rotating folding blades which areconfigured to contact the diaper 20 along the fold line 92. In such aconfiguration, the rotation of the folding blades force the diaper intoa nip between two rotating rolls causing the diaper 20 to fold about thefold line 92.

As illustrated in FIG. 1, the waist regions 22 and 24 are maintained inthe facing relationship by passing the diaper 20 through another bonder94 which may be similar to bonder 100. The bonder 94 permanently bondsand secures the side portions 70 of the side panels 28 to the side edges30 of the diaper 20 in the respective waist region 22 or 24 alongattachment line 72 to provide the prefastened diaper 20 asrepresentatively illustrated in FIG. 2. Desirably, the bonder 94 is alsoan ultrasonic bonder for improved efficiency and cost effectiveness.Suitable bonders for permanently bonding and securing the side panels 28to the side edges 30 of the diaper 20 are described above as beingsuitable for bonder 100 and may include bonding roll 96 and anvil roll98. Suitable bond patterns are also described above. Desirably, the bondpattern used along attachment line 72 is continuous for improvedstrength.

The methods of the present invention, as representatively illustrated inFIGS. 1 and 2, can reliably and consistently provide prefastenedabsorbent articles having separate and distinct side panels such as thediaper illustrated in FIGS. 3-5. Since the side panels 28 areindividually applied to the outer surface 36 of the diaper 20 in thefront waist region instead of being first attached to the side edges ofthe diaper in the opposite waist region, it is not necessary to fold theside panels over to engage the outer surface. Such a configuration canresult in improved control of the location and placement of the primaryfasteners and reduce the complexity of the equipment needed.

The absorbent articles made by the methods of the present invention maybe manufactured from a variety of materials. For example, asrepresentatively illustrated in FIGS. 3-5, the outer cover 42 of thediaper 20 may suitably be composed of a material which is either liquidpermeable or liquid impermeable. Since the absorbent chassis 44 of thedifferent aspects of the present invention is designed to contain thebody exudates discharged from the wearer, it is generally not necessarythat the outer cover 42 be liquid impermeable. For example, the outercover 42 may include various woven or nonwoven materials such asspunbond material, meltblown material, cotton material, rayon materialor combinations thereof such as a spunbond-meltblown-spunbond (SMS)laminate material. The outer cover 42 may otherwise be at leastpartially liquid impermeable to further prevent any leakage of bodyexudates. For example, a typical outer cover 42 can be manufactured froma thin plastic film or other flexible liquid-impermeable material, wovenor nonwoven fibrous layers, microporous “breathable” materials, elasticmaterials and combinations thereof.

The absorbent chassis 44 of the diaper 20 is suitably connected to theouter cover 42 to provide the disposable diaper 20. The absorbentchassis 44 may be connected to the outer cover 42 in manners well knownto those skilled in the art. For example, the absorbent chassis 44 maybe bonded to the outer cover 42 using adhesive, thermal or ultrasonicbonding techniques known to those skilled in the art. Alternatively, theabsorbent chassis 44 may be connected to the outer cover 42 usingconventional fasteners such as buttons, hook and loop type fasteners,adhesive tape fasteners, and the like. The other components of thediaper 20 may be suitably connected together using similar means.

Desirably, the absorbent chassis 44 is connected to the outer cover 42only at or adjacent the waist edges 32 of the outer cover 42 therebycreating a front attached portion, a back attached portion and anunattached portion which extends between and connects the attachedportions. The unattached portion of the absorbent chassis 44 remainssubstantially unattached to the outer cover 42 and is generallyconfigured to fit between the legs of the wearer and at least partiallycover the lower torso of the wearer when in use. As a result, theunattached portion is generally the portion of the absorbent chassis 44which is configured to initially receive the body exudates from thewearer. Thus, the absorbent chassis 44 is connected to the outer cover42 in such a manner to secure the chassis 44 in place while notadversely restricting the movement of the outer cover 42 in use.Alternatively, the absorbent chassis 44 may be attached to the outercover 42 along the entire longitudinal length of the absorbent chassis44 or any portion thereof or along only the outer periphery of theabsorbent chassis 44.

As representatively illustrated in FIG. 4, the absorbent chassis 44according to the present invention may include a backsheet 46, abodyside liner 48 which is connected to the backsheet 46 in a superposedrelation, and an absorbent core 50 which is located between the bodysideliner 48 and the backsheet 46. In alternative configurations wherein theouter cover 42 is at least partially resistant to the flow of liquidstherethrough, the backsheet 46 may optionally be omitted from theabsorbent chassis 44.

The absorbent chassis 44 is generally conformable and capable ofabsorbing and retaining body exudates. The absorbent chassis 44 may haveany of a number of shapes and sizes. For example, as representativelyillustrated in FIG. 4, the absorbent chassis 44 may be rectangular,I-shaped or T-shaped. The size and absorbent capacity of the absorbentchassis 44 should be compatible with the size of the intended wearer andthe fluid loading imparted by the intended use of the diaper 20.Typically, it is desirable that the absorbent chassis 44 have anabsorbent capacity of at least about 300 grams of urine. It is generallypreferred that the absorbent chassis 44 be narrower in the crotch region26 than in the waist regions 22 and 24. It has been found that theabsorbent chassis 44 of the present invention is particularly usefulwhen the width dimension in the crotch region 26 is from about 2.5 toabout 10.2 centimeters (1.0 to about 4.0 inches), desirably no more thanabout 7.6 centimeters (3.0 inches) and more desirably no more than about5.1 centimeters (2.0 inches). The narrow crotch width dimension of theabsorbent chassis 44 allows the absorbent chassis 44 to better fitbetween the legs of the wearer.

The bodyside liner 48 of the absorbent chassis 44, as representativelyillustrated in FIG. 4, suitably presents a bodyfacing surface which isintended to be worn adjacent the body of the wearer and is compliant,soft feeling and nonirritating to the wearer's skin. Further, thebodyside liner 48 may be less hydrophilic than the absorbent core 50, topresent a relatively dry surface to the wearer, and may be sufficientlyporous to be liquid permeable, permitting liquid to readily penetratethrough its thickness. A suitable bodyside liner 48 may be manufacturedfrom a wide selection of web materials, such as woven and nonwovenfabrics, porous foams, reticulated foams, apertured plastic films,natural fibers (for example, wood or cotton fibers), synthetic fibers(for example, polyester or polypropylene fibers), or a combination ofnatural and synthetic fibers. The bodyside liner 48 is suitably employedto help isolate the wearer's skin from fluids held in the absorbent core50 of the absorbent chassis 44.

The backsheet 46 of the absorbent chassis 44, as representativelyillustrated in FIG. 4, may suitably be composed of a material which iseither liquid permeable or liquid impermeable. It is generally preferredthat the backsheet 46 be formed from a material which is substantiallyimpermeable to fluids. A typical backsheet can be manufactured from athin plastic film or other flexible liquid-impermeable material. Thebacksheet 46 may also be constructed of a material which is similar tothe material described as being suitable for the outer cover 42.

The bodyside liner 48 and backsheet 46 are generally adhered to oneanother so as to form a pocket in which the absorbent core 50 is locatedto provide the absorbent chassis 44. The bodyside liner 48 and backsheet46 may be adhered directly to each other around the outer periphery ofthe absorbent chassis 44 by any means known to those skilled in the artsuch as adhesive bonds, sonic bonds or thermal bonds. For example, auniform continuous layer of adhesive, a patterned layer of adhesive, asprayed or meltblown pattern of adhesive or an array of lines, swirls orspots of adhesive may be used to affix the bodyside liner 48 to thebacksheet 46. It should be noted that both the bodyside liner 48 and thebacksheet 46 need not extend completely to the outer periphery of theabsorbent chassis 44. For example, the backsheet 46 may extend to theouter periphery of the absorbent chassis 44 while the bodyside liner 48may be attached to the backsheet 46 inboard of the outer periphery ofthe absorbent chassis 44, or more towards the longitudinal centerline ofthe diaper 20. In alternative configurations, especially wherein thebacksheet 46 is omitted, the bodyside liner 48 may be suitably adhereddirectly to the absorbent core 50 or to the outer cover 42.

The absorbent core 50, as representatively illustrated in FIG. 4, ispositioned between the bodyside liner 48 and the backsheet 46 to formthe absorbent chassis 44. The absorbent core 50 is desirably conformableand capable of absorbing and retaining body exudates. The absorbent core50 may have any of a number of shapes and sizes. For example, theabsorbent core may be rectangular, I-shaped or T-shaped. It is generallypreferred that the absorbent core 50 be narrower in the crotch region26. The size of the absorbent core 50 should be compatible with the sizeof the intended wearer and the desired absorbent capacity of theabsorbent chassis 44.

The absorbent core 50 of the absorbent chassis 44 may suitably comprisevarious types of wettable, hydrophilic fibrous materials. Examples ofsuitable materials include naturally occurring organic fibers composedof intrinsically wettable material, such as cellulosic fibers; syntheticfibers composed of cellulose or cellulose derivatives, such as rayonfibers; inorganic fibers composed of an inherently wettable material,such as glass fibers; synthetic fibers made from inherently wettablethermoplastic polymers, such as particular polyester and polyamidefibers; and synthetic fibers composed of a nonwettable thermoplasticpolymer, such as polypropylene fibers, which have been hydrophilized byappropriate means known to those skilled in the art. The absorbent core50 may also comprise selected blends of the various types of fibersmentioned above.

In a particular aspect of the invention, the absorbent core 50 mayinclude a matrix of hydrophilic fibers, such as a web of cellulosicfibers, mixed with particles of a high-absorbency material such as thatcommonly known as superabsorbent material. As used herein, the term“high-absorbency material” refers to materials that are capable ofabsorbing at least 10 times their own weight in liquid. In a particularembodiment, the absorbent core 50 comprises a mixture of superabsorbenthydrogel-forming particles and wood pulp fluff. The wood pulp fluff maybe exchanged with synthetic, polymeric, meltblown fibers or with acombination of meltblown fibers and natural fibers. The high-absorbencymaterial may be substantially homogeneously mixed with the hydrophilicfibers or may be nonuniformly mixed. The high-absorbency material mayalso be arranged in a generally discrete layer within the matrix ofhydrophilic fibers. Alternatively, the absorbent core 50 may comprise alaminate of fibrous webs and high-absorbency material or other suitablemeans of maintaining a high-absorbency material in a localized area.

As representatively illustrated in FIG. 4, the absorbent chassis 44 ofthe disposable diaper 20 may include a pair of containment flaps 54which are configured to provide a barrier to the lateral flow of bodyexudates. The containment flaps 54 may be located along the laterallyopposed side edges of the absorbent chassis 44. Each containment flap 54typically defines an unattached edge which is configured to maintainupright, perpendicular configuration in at least the crotch region 26 ofthe diaper 20 to form a seal against the wearer's body. The containmentflaps 54 may extend longitudinally along the entire length of theabsorbent chassis 44 or may only extend partially along the length ofthe absorbent chassis 44. When the containment flaps 54 are shorter inlength than the absorbent chassis 44, the containment flaps 54 can beselectively positioned anywhere along the side edges of the absorbentchassis 44. In a particular aspect of the invention, the containmentflaps 54 extend along the entire length of the absorbent chassis 44 tobetter contain the body exudates.

Such containment flaps 54 are generally well known to those skilled inthe art. For example, suitable constructions and arrangements forcontainment flaps 54 are described in U.S. Pat. No. 4,704,116 issuedNov. 3, 1987, to K. Enloe the disclosure of which is hereby incorporatedby reference.

The disposable diaper 20 of the different aspects of the presentinvention may further include elastics at the waist edges 32 and sideedges 30 of the diaper 20 to further prevent the leakage of bodyexudates and support the absorbent chassis 44. For example, asrepresentatively illustrated in FIG. 4, the diaper 20 of the presentinvention may include a pair of leg elastic members 52 which areconnected to the laterally opposed side edges 30 in the crotch region 26of the diaper 20 and a pair of waist elastic members 56 which areconnected to the longitudinally opposed waist edges 32 of the diaper 20.The leg elastics 52 and waist elastics 56 are generally adapted to fitabout the legs and waist of a wearer in use to maintain a positive,contacting relationship with the wearer to effectively reduce oreliminate the leakage of body exudates from the diaper 20.

Materials suitable for use as the leg elastics 52 and waist elastics 56are well known to those skilled in the art. Exemplary of such materialsare sheets or strands or ribbons of a polymeric, elastomeric materialwhich are adhered to the outer cover 42 in a stretched position, orwhich are attached to the outer cover 42 while the outer cover ispleated, such that elastic constrictive forces are imparted to the outercover 42. The leg elastics may also include such materials aspolyurethane, synthetic and natural rubber.

As representatively illustrated in FIGS. 3-5 and described with respectto the method aspects of the invention, the diaper 20 further includes apair of laterally opposed side panels 28 connected to the side edges 30of the diaper 20 in one of the waist regions 22 and 24. For example, asillustrated in FIGS. 4 and 5, the side panels 28 of the diaper 20 arepermanently secured to and extend laterally beyond the side edges 30 ofthe diaper 20 in the back waist region 24 of the diaper 20. The sidepanels 28 include individual, distinct pieces of material which areconnected to the diaper 20 along attachment line 72 using attachmentmeans known to those skilled in the art such as adhesive, thermal orultrasonic bonding. As discussed above, the side panels 28 are desirablyattached to the diaper 20 using ultrasonic bonding for improvedmanufacturing efficiency and reduced raw material cost.

Materials suitable for the side panels 28 of the diaper 20 are generallyknown to those skilled in the art. For example, suitable materials forthe side panels 28 include those materials described above as beingsuitable for the outer cover 42, backsheet 46 or bodyside liner 48 ofthe diaper 20 such as woven and nonwoven materials. Desirably, the sidepanels 28 are elastic or stretchable. For example, the side panels 28may comprise a stretch-thermal laminate (STL), neck-bonded laminate(NBL), or stretch-bonded laminate (SBL) material. Methods of making suchmaterials are well known to those skilled in the art and described inU.S. Pat. No. 4,663,220 issued May 5, 1987 to Wisneski et al., U.S. Pat.No. 5,226,992 issued Jul. 13, 1993 to Mormon, and European PatentApplication No. EP 0 217 032 published on Apr. 8, 1987 in the names ofTaylor et al., the disclosures of which are hereby incorporated byreference.

The absorbent article of the different aspects of the present inventionfurther includes a multi-functional fastening system 60 for securing theabsorbent article about the waist of the wearer. The multi-functionalfastening system 60 includes fasteners located on one of the waistregions 22 and 24 of the diaper 20 which are configured to releasablyengage the opposite waist region of the diaper 20 to maintain the diaperabout the waist of the wearer. The use of fasteners which arerefastenable or releasably engageable allows for ease of securing andremoving the diaper 20 from the waist of the wearer without undesirablysoiling the wearer.

As representatively illustrated in FIGS. 3-5, the multi-functionalfastening system 60 of the present invention may include a pair ofprimary fasteners 62 which are located on the side panels 28 of thediaper 20 in the back waist region 24 of the diaper 20. In such aconfiguration, the side panels 28 and primary fasteners 62 areconfigured to encircle the hips of the wearer and engage the outersurface 36 of the front waist region 22 of the diaper 20 to maintain thediaper 20 on the wearer. Alternatively, the side panels 28 and primaryfasteners 62 may be located on the front waist region 22 and may beconfigured to releasably engage the outer surface 36 of the back waistregion 24 of the diaper 20. The primary fasteners 62 may be adhered tothe side panels 28 by any means known to those skilled in the art suchas adhesive bonds, sonic bonds or thermal bonds.

Desirably, the primary fasteners 62 are releasably engageable directlywith the outer surface of the outer cover 42 of the diaper 20 to provideimproved fit and ease of fastening. Alternatively, as representativelyillustrated in FIG. 3, the disposable diaper 20 of the present inventionmay further include an attachment panel 66 located on the outer cover 42in one of the waist regions 22 and 24 of the diaper 20. In such aconfiguration, the primary fasteners 62 are releasably engageable withthe attachment panel 66 to maintain the diaper 20 about the waist of thewearer. When the primary fasteners 62 are releasably engaged, the sideedges 30 of the diaper 20 define leg openings which are configured toencircle the legs of the wearer and the waist edges 32 define a waistopening which is configured to encircle the waist of the wearer. Asillustrated in FIG. 5, the attachment panel 66 may include two separatepanels located along the opposite side edges in one of the waist regions22 and 24 of the diaper 20. Alternatively, the attachment panel 66 mayinclude a single piece of material which extends substantially acrossthe respective waist region of the diaper 20.

In the different aspects of the present invention, the primary fasteners62 are releasably engaged with the outer surface of the opposite waistregion 22 and 24 of the diaper 20 before the diaper 20 is placed on thewearer to provide a prefastened diaper. In such a configuration, theprefastened diaper 20 can be pulled on or off over the legs and hips ofthe wearer. If the diaper 20 becomes soiled during use, the primaryfasteners 62 can be disengaged to easily remove the diaper 20 from thewaist of the wearer with reduced risk of undesirably soiling the clothesor legs of the wearer. Thus, the diaper 20 is configured to be pulled onor off over the hips of the wearer such as conventional training pantsand can be readily applied or removed by disengaging the fastenerssimilar to conventional diaper articles.

Suitable fasteners are well known to those skilled in the art and caninclude adhesive tape tab fasteners, hook and loop fasteners, mushroomfasteners, snaps, pins, belts and the like, and combinations thereof.For example, as representatively illustrated in FIG. 4, the primaryfasteners 62 may be hook type fasteners and the outer cover 42 orattachment panel 66 may be configured to function as a complimentaryloop type fastener. Desirably, the fasteners 62 are hook type fastenerswhich are releasably engageable directly with the outer cover 42. Suchan arrangement provides the ability to vary the size of the waistopening in very small increments over a wide range to fit the waist ofthe wearer.

The multi-functional fastening system 60 on the disposable diaper 20 ofthe present invention may further include at least one secondaryfastener (not shown) to provide improved securement of the diaper 20about the waist of the wearer when the primary fasteners 62 arereleasably engaged. Such a secondary fastener can be configured tofurther conform the waist regions 22 and 24 of the diaper 20 to thewaist of the wearer. A suitable arrangement for such secondary fastenersis described in U.S. patent application Ser. No. 08/907,585 entitled “AMULTI-FUNCTIONAL FASTENER FOR DISPOSABLE ABSORBENT ARTICLES” and filedAug. 8, 1997 in the name of J. Suprise.

The use of such secondary fasteners has been found to be particularlydesirable since the primary fasteners 62 are releasably engaged with therespective waist region of the diaper 20 prior to use. In such aconfiguration, the waist opening of the diaper 20 when the primaryfasteners 62 are engaged must be sufficient to allow the prefasteneddiaper 20 to be pulled over the hips of the wearer. However, thecircumference of the waist of the wearer is typically less than thecircumference around the hips of the wearer. Thus, the waist opening ofthe prefastened diaper 20 may not conform to the waist of the wearerwhich may undesirably result in leaks. In such a configuration, thesecondary fastener of the diaper 20 is configured to conform the waistregions of the diaper 20 to the wearer by reducing the waist perimeterdimension of the diaper 20 after the prefastened diaper is pulled on thewearer. Thus, the care giver is not required to reposition the primaryfasteners 62 to conform the waist regions 22 and 24 to the waist of thewearer. As a result, when the diaper 20 is to be removed from thewearer, the care giver may simply disengage the secondary fastener ifnecessary and pull the prefastened diaper down over the hips and legs ofthe wearer without having to reposition the primary fasteners 62.Alternatively, if the diaper 20 does not include such secondaryfasteners, the primary fasteners 62 can be repositioned if necessaryafter the prefastened diaper 20 has been pulled on over the legs andhips of the wearer.

As described above in connection with the method aspects of theinvention, the prefastened absorbent article of the present inventionfurther includes a pair of releasable side bonds 64 for improvedreliability of maintaining the article in the prefastened conditionparticularly when it is being pulled on or off over the hips of thewearer. Absorbent articles including such releasable side bonds arefurther described in U.S. Patent Application entitled “DISPOSABLEABSORBENT ARTICLES HAVING PASSIVE SIDE BONDS AND ADJUSTABLE FASTENINGSYSTEMS” filed in the name of Elsberg on the same date as the instantapplication and having Ser. No. 09/100,574, the disclosure of which ishereby incorporated by reference.

For example, as representatively illustrated in FIG. 3, the diaper 20may include a pair of releasable side bonds 64 which releasably connectside panels 28 to the front waist region 22 of the diaper 20. In such aconfiguration, the releasable side bonds 64 assist the fastening system60 in maintaining the diaper 20 in a prefastened condition as the diaper20 is pulled up or down over the hips of the wearer. Moreover, thereleasable side bonds 64 prevent movement and shifting of the waistregions 22 and 24 and side panels 28 relative to each other for improvedfit and performance. The releasable side bonds 64 also prevent rolloveror folding of the side edges 30 and waist edges 32 of the prefasteneddiaper 20 as it is pulled over the wearers hips.

In the illustrated embodiments, the releasable side bonds 64 connect therespective side panel 28 and front waist region 22 in a facingrelationship. As described above, the releasable side bonds 64 can beprovided by any type of bonding such as thermal, adhesive and ultrasonicbonding as are well known to those skilled in the art and may bediscrete point bonds, dashed lines, continuous lines, discontinuouslines and the like or combinations thereof. Moreover, the side bonds 64may have any shape such as circular, square, triangular and the like.Desirably, the releasable side bonds 64 are ultrasonic point bonds forimproved manufacturing efficiency.

In certain aspects of the invention, the location of the side bonds 64and the respective distance 68 (FIG. 2) can be selectively varied totailor the fit of the diaper 20 for different sized wearers. Forexample, the location of the bonds 64 may be varied during themanufacturing process such that the same process can produce prefasteneddiapers for use in conventional Step 3 or Step 4 sizes.

The releasable side bonds 64 are configured to assist the primaryfasteners 62 in maintaining the diaper 20 in a prefastened configurationas the diaper 20 is pulled on and off over the hips of the wearer andduring use. Thus, it is desirable that the releasable side bonds 64provide adequate shear strength for assisting the primary fasteners 62.For example, in a particular embodiment, the releasable side bonds 64define a shear strength of at least about 50grams and desirably at leastabout 100 grams. For example, the passive side bonds 80 and 82 maydefine a shear strength of from about 100 to about 4000 grams anddesirably from about 500 to about 2000 grams. As used herein, the term“shear strength” refers to the value obtained when subjecting the sidebonds to the Shear Strength Test described herein. Shear strength valuesless than those described above may not prevent the separation of thefront and rear waist regions 22 and 24 from each other during theapplication and use of the diaper 20.

The releasable side bonds 64 are also configured to be readily tearablesuch that the caregiver can easily pealingly remove the diaper 20 fromthe wearer after it has been soiled. Thus, it is desirable that thereleasable side bonds 64 define a relatively low peel strength such thatthe caregiver can readily disengage the fasteners 62, break thereleasable side bonds 64 and separate the front and back waist regions22 and 24 to remove the diaper 20 from the waist of the wearer similarto conventional diapers which are not prefastened. For example, in aparticular embodiment, the releasable side bonds 64 define a peelstrength of no more than about 1500, desirably no more than about 1000grams and more desirably no more than about 800 grams. As used herein,the term “peel strength” refers to the value obtained when subjectingthe side bonds to the Peel Strength Test described herein. Peel strengthvalues greater than those described above may not be readily tearableand may undesirably result in tearing of other portions of the diaper20.

The different aspects of the present invention advantageously providemethods of making a prefastened disposable absorbent article whichincludes the combination of releasable or releasable side bonds and anadjustable fastening system. The fastening system is prefastened toreleasably engage the front and back waist portions to allow theabsorbent article to be pulled up or down over the hips of the wearersuch as conventional training pants. Moreover, the fastening system canbe used to releasably engage and adjust the front and back waistportions of the absorbent article to maintain the absorbent articleabout the waist of the wearer after the article has been pulled on in asimilar manner to conventional diapers. The releasable side bonds assistthe fastening system in maintaining the article in a prefastenedcondition as the article is pulled up or down over the hips of thewearer. Moreover, the releasable side bonds prevent movement andshifting of the waist portions relative to each other for improvedmanufacturability, fit and performance. The releasable side bonds alsoprevent the rollover or folding on the side and waist edges of theprefastened absorbent article as it is pulled over the wearers hips.

As a result, the absorbent article of the present invention is designedto conform to the body of the wearer to effectively contain bodilyexudates while still being capable of being reliably pulled up or downover the hips of the wearer to assist in the toilet training of thewearer. Moreover, similar to conventional diapers, the absorbent articleof the present invention can advantageously be applied to and removedfrom the wearer with relative ease and cleanliness.

Peel Strength Test

This test method is designed to quantify, in grams, the peak strength ofthe ultrasonic point bonds holding the front waist region of theabsorbent article to the rear waist region. The direction of removal(peel), in this application, is that direction in which the fastenermaterial would generally be removed from a substrate when the product isin use. This direction is generally perpendicular to a longitudinalcenterline of the product.

Equipment

1. Tensile tester capable of obtaining a peak load and equipped with anappropriate load cell. A suitable tensile testing system is a SintechTensile Tester, commercially available from MTS Sintech, ResearchTriangle Park, North Carolina, under the trade designation Instron Model4201 Tensile Tester with Sintech QAD (Quality Assurance Department)Software.

2. Software commercially obtained from MTS Sintech under the tradedesignation Sintech Testworks™.

3. Pnuematic-action grips commercially available from InstronCorporation, Canton, Mass., under the trade designation “Instron Model2712-004.”

4. 1 by 4 inch grip faces, serrated, commercially available from InstronCorporation, Canton, Mass.

5. Test facility having a temperature of 23±1° C., and a relativehumidity of 50±2 percent.

Test Procedure

1. A sample to be tested is conditioned in the test facility for atleast 4 hours prior to testing.

2. The load cell is calibrated and the software loaded.

3. The grips are installed on the tensile tester with the jaws closed.

4. The test condition for the tensile tester are set as follows:

Crosshead speed: 500 millimeters/minute Full-scale load:  5 kitogramsThreshold:  5 percent Fail criterion:  95 percent Gage length:  50millimeters

5. The weight of the clamp is tared out.

6. The primary fastener tab of the fastening element on the back waistregion of the article is inserted into the upper jaw such that the edgeof the grip face is flush with the inner edge of the hook material.

7. The front waist region of the article is inserted into the lower jawsuch that the inner surface of the back waist region and the outersurface of the front waist region form a 180° angle. The lower jaw isclosed.

8. The crosshead is started in motion.

9. The peak load of failure is recorded. It is intended that the mode offailure is that the back waist region of the diaper separates from thefront waist region of the diaper. Results are rejected if the place offailure is any location other than the ultrasonic point bonds.

Shear Strength Test

This test method is designed to quantify, in grams, the peak dynamicshear strength of the ultrasonic point bonds holding the front waistregion of the absorbent article to the rear waist region. The directionof force in this application is generally perpendicular to thelongitudinal centerline of the product.

Equipment

1. Tensile tester capable of obtaining a peak load and equipped with anappropriate load cell. A suitable tensile testing system is a SintechTensile Tester, commercially available from MTS Sintech, ResearchTriangle Park, North Carolina, under the trade designation Instron Model4201 Tensile Tester with Sintech QAD (Quality Assurance Department)Software.

2. Software commercially obtained from MTS Sintech under the tradedesignation Sintech Testworks™.

3. Pnuematic-action grips commercially available from InstronCorporation, Canton, Mass., under the trade designation “Instron Model2712-004.”

4. 1 by 4 inch grip faces, serrated, commercially available from InstronCorporation, Canton, Mass.

5. Test facility having a temperature of 23±1° C., and a relativehumidity of 50±2 percent.

Test Procedure

1. A sample to be tested is conditioned in the test facility for atleast 4 hours prior to testing.

2. The load cell is calibrated and the software loaded.

3. The grips are installed on the tensile tester with the jaws closed.

4. The test condition for the tensile tester are set as follows:

Crosshead speed: 500 millimeters/minute Full-scale load:  5 kilogramsThreshold:  5 percent Fail criterion:  95 percent Gage length:  50millimeters

5. The weight of the clamp is tared out.

6. The primary fastener tab of the fastening element on the back waistregion of the article is inserted into the upper jaw such that the edgeof the grip face is flush with the inner edge of the hook material.

7. The front waist region of the article is inserted into the lower jawsuch that the inner surface of the back waist region and the innersurface of the front waist region are facing the same direction and areparallel to one another. The lower jaw is closed.

8. The crosshead is started in motion.

9. The peak load of failure is recorded. It is intended that the mode offailure is that the back waist region of the article separates from thefront waist region of the article. Results are rejected if the place offailure is any location other than the ultrasonic point bonds.

While the invention has been described in detail with respect tospecific aspects thereof, it will be appreciated that those skilled inthe art, upon attaining an understanding of the foregoing, may readilyconceive of alterations to, variations of and equivalents to theseaspects. Accordingly, the scope of the present invention should beassessed as that of the appended claims and any equivalents thereto.

I claim:
 1. A prefastened disposable absorbent article which defines afront waist region, a back waist region, a crotch region which extendsbetween and connects said waist regions, a pair of opposed side edges, apair of opposed waist edges and an absorbent, said absorbent articlecomprising: a) a pair of opposed side panels which define side portionswhich are attached to said opposed side edges of said back waist regionof said absorbent article and which include a primary fastener locatedthereon which releasably engages an outer surface of said absorbentarticle in said front waist region to provide said prefastened absorbentarticle; and b) a pair of releasable side bonds which are located onsaid opposed side panels between said primary fastener and said sideportion and which releasably connect said side panels to said frontwaist region to assist in maintaining said prefastened absorbent articlein a prefastened condition.
 2. The prefastened absorbent article ofclaim 1 wherein said side portions of said side panels areultrasonically bonded to said side edges of said back waist region. 3.The prefastened absorbent article of claim 1 wherein said prefastenedabsorbent article is made by a process which comprises: a) releasablyengaging said primary fastener on each of said opposed side panels tosaid outer surface of said absorbent article in said front waist region;b) releasably bonding said side panels to said front waist region toassist said primary fasteners in providing said releasable attachment ofsaid side panels to said front waist region; c) folding said absorbentarticle about a fold line extending in a lateral direction through saidcrotch region of said absorbent article thereby positioning said waistregions in a facing relationship; and d) securing said side portions ofsaid side panels to said side edges of said absorbent article in saidback waist region to provide said prefastened absorbent article.
 4. Theprefastened absorbent article of claim 3 wherein said primary fastenerson said side panels are releasably engaged to said outer surface of saidabsorbent article before said side portions of said side panels aresecured to said side edges of said absorbent article in said back waistregion.
 5. The prefastened absorbent article of claim 3 wherein saidside panels are releasably bonded to said front waist region before saidside portions of said side panels are secured to said side edges of saidabsorbent article in said back waist region.
 6. The prefastenedabsorbent article of claim 1 wherein said primary fasteners are hooktype fasteners.
 7. The prefastened absorbent article of claim 1 andfurther comprising at least one attachment panel which is located onsaid outer surface of said absorbent article in said front waist regionwherein said primary fasteners releasably engage said attachment panel.8. The prefastened absorbent article of claim 1 wherein said releasableside bonds connect said side panels to said side edges of said absorbentarticle in said front waist region to assist in maintaining saidprefastened absorbent article in said prefastened condition.
 9. Theprefastened absorbent article of claim 1 wherein said releasable sidebonds are located on said side panels laterally outward from saidprimary fasteners a distance of at least about 1.0 centimeters.
 10. Theprefastened absorbent article of claim 1 wherein said releasable sidebonds include at least one point bond.
 11. The prefastened absorbentarticle of claim 10 wherein said at least one point bond is anultrasonic point bond.
 12. The prefastened absorbent article of claim 1wherein said releasable side bonds define a peel strength of no morethan about 1500 grams.
 13. The prefastened absorbent article of claim 1and further comprising an outer cover and an absorbent chassis connectedto said outer cover.
 14. The prefastened absorbent article of claim 13wherein said primary fasteners on said side panels releasably engagesaid outer cover of said absorbent article.
 15. A prefastened disposableabsorbent article which defines a front waist region, a back waistregion, a crotch region which extends between and connects said waistregions, a pair of opposed side edges, a pair of opposed waist edges andan absorbent, said absorbent article comprising a pair of opposed sidepanels which define side portions which are attached to said opposedside edges of said back waist region of said absorbent article and whichinclude a primary fastener located thereon which releasably engages anouter surface of said absorbent article in said front waist region toprovide said prefastened absorbent article; and a pair of spaced apartreleasable side bonds which are located on said opposed side panelsbetween said primary fastener and said side portion and which releasablyconnect said side panels to said front waist region to assist inmaintaining said prefastened absorbent article in a prefastenedcondition, wherein said prefastened absorbent article is made by aprocess which comprises: a) releasably engaging said primary fastener oneach of said opposed side panels to said outer surface of said absorbentarticle in said front waist region; b) folding said absorbent articleabout a fold line extending in a lateral direction through said crotchregion of said absorbent article thereby positioning said waist regionsin a facing relationship; and c) securing said side portions of saidside panels to said side edges of said absorbent article in said backwaist region to provide said prefastened absorbent article.
 16. Theprefastened absorbent article of claim 15 wherein said primary fastenerson said side panels are releasably engaged to said outer surface of saidabsorbent article before said side portions of said side panels aresecured to said side edges of said absorbent article in said back waistregion.